What is cellular concrete?
Concrete blocks
Cellular concrete is a specialised engineered material created by combining Portland cement, sand, fly ash, water and pre-formed foam in various proportions to achieve an oven-dry density of 50 pounds per cubic foot or less. According to the American Concrete Institute, density must not exceed this threshold, though actual densities range from 20 to 120 PCF.
A defining characteristic is its self-compacting nature. No compaction is required, the concrete flows from the pump to fill the mould. This enables long-distance and high-elevation pumping capabilities. The material is also known as foam cement, foamed concrete or lightweight flowable fill.
Materials used
Cement: Homogeneous combinations of Portland cement, cement-silica, cement-pozzolana, lime-pozzolana or lime-silica pastes with identical cell structures.
Fly ash: A thermal power plant by-product used as a key ingredient, solving disposal problems while reducing costs.
Foam: Genfil and organic substances create stable bubbles ranging from 0.1 to 1.5 mm in diameter using foam generators.
Density classifications
High density: 1,200 to 1,800 kg/m³ for load-bearing walls and precast blocks.
Medium density: 800 to 1,000 kg/m³ for non-load-bearing precast blocks.
Light density: 400 to 600 kg/m³ for thermal and sound insulation.
Key advantages
Lightweight, reduces structural dead loads.
Fire-resistant and non-combustible.
Thermal insulation properties.
Acoustical insulation capabilities.
Environmentally friendly, uses fly ash.
Cost-efficient.
Termite-proof and freeze-resistant.
Applications
Thermal insulation in roofs and non-load-bearing walls, bulk filling for wells and basements, heat-insulated wall panels, acoustic balance, drainage systems, bridge and tunnel construction, and specialised ceramic tile production.
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